Foldable support leg and pallet assembly formed therefrom

ABSTRACT

A support leg includes a sheet of material configured into a sequence of adjacent panels and including a first tab, a first cutout configured to receive the first tab being formed within one of the panels, wherein the sheet is foldable into a nested panel structure defining an interior cavity. A pallet deck includes a sheet of material having a plurality of first cutouts and second cutouts defined therein, wherein each first cutout is dimensioned to allow insertion of the at least one tab and at least one panel of the foldable support leg and each second cutout is dimensioned to allow insertion of the at least one tab, each second cutout being spaced apart from each first cutout such that the at least one panel is able to substantially extend therebetween. A pallet assembly is formed by mating a plurality of support legs to a pallet deck.

This application claims the benefit of U.S. Provisional Application No.60/721,621, filed on Sep. 29, 2005, the contents of which are hereinincorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention generally relates to pallet assemblies, andparticularly to pallet assemblies made from sheets of corrugatedmaterials like plastic and paper.

BACKGROUND OF THE INVENTION

Wooden pallets used in connection with shipping and other activities areubiquitous. However, there are many drawbacks associated with woodenpallets. Wooden pallets are heavy and are prone to infestation byvarious insects and to fungal growth. The need to check wooden palletsfor infestation and/or fungus, and to treat affected pallets can causeserious delay and expense for pallet users, especially in internationalshipping activities. Before use, wooden ballets must be shipped toprospective points of use. During such shipping, wooden pallets occupy arelatively large volume, thus limiting the number that can be shipped ina given conveyance. Once used, wooden pallets are difficult to recycleand consequently end up in landfills in excessive numbers.

Materials like plastic and paper can be advantageous relative to wood asplastic and paper are lighter, and either inherently resistant toinfestation and fungal growth or easily treatable to resist both.Recycling facilities readily accept plastic and/or paper. Variousattempts have been made to design corrugated plastic or paper pallets.Some plastic pallets are individually molded for a specific use. Suchpallets are relatively expensive to produce initially and require nearlythe same volume during shipping as wooden pallets.

Other attempts have been made to use corrugated paper or plastic, butwithout deviating far from conventional pallet design. These types ofpallets are generally constructed using conventional pallet elements cutfrom multiple plies of corrugated material and then assembled. Becauseof the large amount of material used, such pallets do not fully takeadvantage of the lightweight nature of plastic and/or paper, and requireas much, or nearly as much, space during shipping as conventionalpallets.

Finally, some attempts have been made to construct pallets using fewerplies of paper or plastic, while typically trying to increase strengthwith some combination of folding and use of more rigid materials. Suchpallets are difficult to assemble, require additional adhesives andfasteners, and only achieve a limited benefit over wood when more rigidmaterials are included.

From the foregoing it can be seen that there is a need for a lightweightpallet constructed from plastic and/or paper that exhibits sufficientload-bearing capacity and rigidity while capable of occupying a smallvolume during shipping to a point of use and adapted for easy assemblyat the point of use without the need for adhesives, discrete fasteners,or the like.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a foldable supportleg that is completely flat when unfolded, but provides superiorrigidity and load-bearing capacity once folded, without requiring anyadhesives, discrete fasteners, or the like.

It is a further object of the present invention to provide a foldablesupport leg adapted for securely mating, without requiring adhesives,discrete fasteners, or the like, with a load bearing surface, such asthe deck of a pallet.

According to an embodiment of the present invention, a pallet assemblyincludes a plurality of support legs, at least one support leg foldedfrom a single sheet of material and including a first tab and defining afirst cutout for receiving the first tab therein, and a pallet deck, atleast one second cutout being defined within the pallet deck wherein theat least one support leg is secured to the pallet deck by the insertionof the first tab through the at least one second cutout prior toinsertion into the first cutout.

According to an aspect of the present invention, the support legincludes a sheet of material configured into a sequence of adjacentpanels and including the first tab, the first cutout configured toreceive the first tab being formed within at least one of the panels,wherein the sheet is foldable into a nested panel structure having thefirst tab inserted into the first cutout and defining an interiorcavity.

According to another aspect of the present invention, the pallet deckincludes a sheet of material having a plurality of first cutouts and aplurality of second cutouts defined therein, wherein each first cutoutis dimensioned to allow insertion of at least one tab and at least onepanel of a corresponding foldable support leg and each second cutout isdimensioned to allow insertion of the at least one tab, each secondcutout being spaced apart from each first cutout such that the at leastone panel is able to substantially extend therebetween.

According to a further aspect of the present invention, two diagonalpanels traverse the interior cavity of the support leg, offset byapproximately 90 degrees, substantially enhancing the structuralconformity and load bearing capacity of the support leg.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pallet assembly including a palletdeck and a plurality of foldable support legs, according to anembodiment of the present invention;

FIG. 2 is a perspective view of one of the support legs of FIG. 1completely unfolded;

FIGS. 3-8 are perspective views of the support leg of FIG. 2, in variousstates of folding;

FIG. 9 is the support leg of FIG. 2 fully folded;

FIG. 10 is a perspective view of the pallet deck of FIG. 1;

FIGS. 11 and 12 are perspective views showing various stages of securingthe supports legs to the pallet deck of FIG. 10;

FIG. 13 is a perspective view of a fully unfolded support leg, accordingto another embodiment of the present invention;

FIGS. 14-16 are perspective views of the support leg of FIG. 13, invarious states of folding;

FIG. 17 is a perspective view of the support leg of FIG. 13 fullyfolded;

FIG. 18 is a perspective view of a pallet deck, according to anotherembodiment of the present invention; and

FIGS. 19 and 20 are perspective views of pallet assemblies including thepallet deck of FIG. 18.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a pallet assembly 10 is formed from a plurality offoldable support legs 12 mated to a pallet deck 14. The support leg willbe described in reference to FIGS. 2-9. Referring to FIG. 2, eachsupport leg 12 is folded from a sheet 20 of material. The sheet 20 ofmaterial is configured into a sequence of adjacent panels and tabs. Thepanels include a bottom panel 22, first and second side panels 24, 26, atop panel 28, first and second diagonal panels 30, 32, a diagonal offsetpanel 34, and first and second deck retention panels 36, 38. Togetherthe panels are all foldable to form a nested panel structure, the top,bottom and side panels 22-28 defining an interior cavity, with thediagonal panels 30, 32 and the diagonal offset panel 34 forming aninternal support structure within the cavity, as will be describedbelow. The terms top, bottom and side refer, as used herein, to theorientation of the support leg 12 when mated with the pallet deck 14during conventional use of the pallet assembly 10 with the support legs12 on the ground.

The tabs include first and second deck retention tabs 44, 46 extendingfrom the first and second deck retention panels 36, 38, and side panelengagement tabs 48 formed in the second side panel 20. Each deckretention tab 44, 46 includes two tab ears 48. A plurality of cutoutsare also defined in the panels. The cutouts include first and seconddeck retention tab cutouts 50,52, a second diagonal deck retention tabcutout 54 and side panel engagement tab cutouts 56. The cooperation ofthe tabs and cutouts will be described in detail below.

The folding of the sheet 20 of material to form the nested panelstructure of the support leg 12 will be explained in reference to FIGS.3-9. In FIG. 3, the sheet 20 is folded approximately 90 degrees betweenthe top panel 28 and the first side panel 24. The second diagonal panel32 is folded approximately 135 degrees over the diagonal offset panel34. In FIG. 4, the diagonal offset panel 34 is folded approximately 90degrees relative to the top panel 28, bringing an edge of the seconddiagonal panel 32 into contact with the junction between the top panel28 and the first side panel 24, thereby forming a portion of theinternal support structure. Notably, the second deck retention tabcutout 52 and the second diagonal deck retention tab cutout 54 arebrought into alignment following this fold.

Referring to FIG. 5, the sheet 20 is folded approximately 90 degreesbetween the first side panel 24 and the bottom panel 22. This foldbrings the junction of the second diagonal panel 32 and the diagonaloffset panel 34 into contact with the junction of the second side panel26 and the bottom panel 22. Thus, the diagonal offset panel 34 extendsbetween the top panel 28 and the bottom panel 22, adding furtherstrength to the support leg 12 and also forming part of the internalsupport structure. Also in FIG. 5, the first diagonal panel 30 is foldedapproximately 135 degrees relative to the top panel 28, bringing an edgeof the first diagonal panel 30 into contact with the junction betweenthe bottom panel 22 and the first side panel 24, thereby forming anotherportion of the internal support structure.

The “x” structure thus formed by the first and second diagonal panels30, 32 can be better appreciated in reference to FIG. 6. As the seconddiagonal panel 32 extends from the diagonal offset 34 panel rather thandirectly from the top panel 28, the first and second diagonal panels 30,32 traverse the interior cavity of the nested panel structure (as yetonly partially folded) offset from one another by an angle of 90degrees. The “x” structure thus formed adds greatly to the strength andrigidity of the fully folded support leg 12.

Referring to FIG. 7, the sheet 20 is folded approximately 90 degreesbetween the bottom panel 22 and the second side panel 26. This foldbrings the second side panel 26 adjacent to the diagonal offset panel34, aligning the side panel engagement tabs 48 in the second side panel26 with the side panel engagement tab cutouts 56 in the diagonal offsetpanel 34. The side panel engagement tabs 48 are pushed inward throughthe side panel engagement tab cutouts 56. Because each side panelengagement tab 48 has a head that exceeds the width of a neck defined byeach corresponding side panel engagement tab cutout 56, the side panelengagement tabs 48 are prevented from pully directly out of the sidepanel engagement tab cutouts 56, thus securing the second side panel 26to the diagonal offset panel 34 and inhibiting the unfolding of thepartially folded support leg 12. Securing the support leg 12 in thesemi-folded state of FIG. 7 will be useful in connection with the matingof the support legs 12 to the pallet deck 14, as will be describedbelow.

Referring to FIG. 8, the first and second deck retention tabs 44, 46 arefolded approximately 90 degrees relative to the deck retention panels36, 38. The tab ears 48 are each folded approximately 90 degrees towardthe top panel 28, such that the shape of the end of each deck retentiontab 36, 38 corresponds to the shape of the deck retention tab cutouts50, 52 in the top panel 28.

In FIG. 9, the first and second deck retention tabs 44, 46 are insertedinto the first and second deck retention tab cutouts 50, 52 by foldingthe first and second deck retention panels 36, 38 90 degrees relative tothe second side panel 26. The second diagonal deck retention tab cutout54 enables complete insertion of the second deck retention tab 46 byallowing the second deck retention tab 46 to extend through the seconddiagonal panel 32. Once the tab ears 48 have been inserted through thefirst and second deck retention tab cutouts 50, 52, the tab ears 48 willat least partially unfold, preferably due to the natural tendency of thematerial to unfold, preventing the deck retention tabs 44, 46 frompulling directly out of the corresponding deck retention tab cutouts 50,52. Portions of the second diagonal deck retention tab cutout 54 areflared outward to accommodate the unfolding of the tab ears 48 of thesecond deck retention tab 46.

In this fully folded state, the deck retention panels 36, 38 partiallyoverlie the top panel 28, but are separated to define an accommodationspace 60. The accommodation space 60 is dimensioned to accommodate thepallet deck 14, which, in the embodiment shown, is approximately thesame thickness as the sheet 20 from which the support leg 12 is folded.The dimensions of the accommodation space 60 are established, on thefirst side panel 24 side, by the distance 62 between the top of the tabears 48 and the corresponding deck retention panel 36, 38, and on thesecond side panel 26 side, by the distance 64 by which the upper edge ofthe second side panel 26 extends above the top panel 28.

Referring to FIG. 10, the pallet deck 14 is formed from a single sheetof material 16 having a plurality of cutouts defined therein. Thecutouts enable the support legs to be secured to the pallet deck, as isdescribed in detail below. The cutouts include elongated cutouts 70 anddeck retention tab cutouts 72. The elongated cutouts 70 are dimensionedto accommodate insertion of both the deck retention tabs 44, 46, withtabs ears 48 unfolded, and the deck retention panels 36, 38 of thesupport legs 12, as will be described below. Where an elongated cutout70 is located at the edge of the pallet deck 14, the elongated cutout 70is formed as a recess 74 in the edge. The spacing 76 between theelongated cutouts 70 and the corresponding deck retention cutouts 72 issubstantially equal to the length of the deck retention panels 36, 38.The deck retention tab cutouts 72 match the shape of the deck retentiontab cutouts 50, 52 in the top panels 28 of the support legs 12.

To assemble the pallet assembly 10 securing the support legs 12 to thepallet deck 14, each support leg is first folded to the state shown inFIG. 7, with the side panel engagement tabs 48 folded into the sidepanel engagement tab cutouts 56 to prevent the partially-folded supportleg 12 from unfolding. Referring to FIG. 11, the unfolded deck retentiontabs 44, 46 and the deck retention panels 36, 38 of each support leg 12are inserted through the corresponding elongated cutout 70. The foldingof each support leg 12 is completed as described above in connectionwith FIGS. 8 and 9, with the addition that each deck retention tab 44,46 is first inserted through the corresponding deck retention tab cutout72 of the pallet deck 14 prior to being inserted through the deckretention tab cutout 50, 52 of the top panel 28 of the support leg 12.The pallet deck 14 is then substantially fills the accommodation space60 between the deck retention panels 36, 38 and the top panel 28 of eachsupport leg 12. Various stages of the folding of the deck retention tabs44, 46 and their insertion through the deck retention tab cutouts 72 ofthe pallet deck 14 are illustrated in FIG. 12. The finished palletassembly 10, with each support leg 12 completely secured to the palletdeck 14, is best seen in FIG. 1.

As the support legs and pallet deck used to form the pallet assembly areeach folded from flat sheets, it can be appreciated that the supportlegs and pallet deck of the present invention can be shipped whileunfolded in large quantities to a point-of-use while requiring far lessspace than conventional pallet support elements. The support legs canthen be assembled using a simple folding process at the point-of-use. Noadhesives, discrete fasteners, and the like are required to assemble asupport leg or the pallet assembly, though these can be used, ifdesired. After use, the pallets can be re-used or easily recycled,depending on the condition of the pallet and the needs and desires ofthe user. It can also be appreciated how a lightweight yet strongsupport leg is formed by folding a single sheet of material. It canparticularly be appreciated that the rigidity and load-bearing capacityof the support leg is enhanced by the internal x structure formed by thefirst and second diagonal panels.

Those skilled in the art will appreciate that the present invention isnot limited to the above-described embodiment, but that modifications,variations, and adaptations for particular circumstances fall within thescope of the invention as herein shown and described.

For example, preferably the sheets of material used to form the supportlegs and the pallet deck are corrugated plastic or paper (cardboard).Such materials are lightweight, low-cost, readily recyclable, andpossess (or can be imbued with during or post-manufacture) anti-fungaland anti-infestation properties. The superior strength and rigidity ofcorrugated sheets vice non-corrugated sheets are well known.Alternately, the sheets of material can be injection molded, which canadvantageously impact material management. It is not necessary that thepallet deck and each support leg be made from sheets of the samematerial.

Since the support legs are folded from a flat sheet, the support legsoccupy substantially less volume, pre-folding. The support leg designcan be modified, as will be clear to those skilled in the art, to befolded from sheets of various thicknesses and material composition, andto accommodate pallet decks of various thicknesses. The thickness andmaterial composition of the sheet used to form the support leg/palletdeck is largely a function of design requirements.

While the overall dimensions of pallets are typically standardized, itwill be appreciated that the current invention readily allows not onlyfor pallets meeting differing standards, but also for custom sizes andcustom designs. The overall pallet height can be adjusted, for instance,by utilizing larger support legs and/or a thicker deck. The length andwidth of the pallet can be varied by altering the dimensions of the deckand changing the arrangement and/or number of support legs, as needed.Pallets that are not square or rectangular can be readily produced in asimilar fashion. It will also be appreciated that a foldable support legaccording the to present invention can be used in a variety of differentapplications, of which pallet assemblies are only one.

While the support leg thus shown and described provides excellentrigidity and strength, further modifications are possible to furtherincrease the strength and rigidity. For example, a sheet of material 120for folding a support leg 112 according to another embodiment of thepresent invention is shown in FIGS. 13-17. The reference numerals willbe repeated for elements common to both embodiments.

Referring to FIG. 13, a modified sheet 120 includes first and secondreinforcement panels 122, 124 extending from the end of a first diagonalpanel 130, and a reinforcement panel cutout 132 is defined within thefirst diagonal panel 130. Also, longer first and second deck detectiontabs 144, 146 are included. Additionally, the tab ears 150 of the firstdeck retention tab 144 each include an angled edge. Each of thesemodifications are further described below. Where an element is the sameas in the embodiment described above, the same reference numeral isused.

In FIG. 14, the second reinforcement panel 124 is folded approximately90 degrees relative to the first reinforcement panel 122. In FIG. 15,the first reinforcement panel 122 is folded 135 degrees relative to thefirst diagonal panel 130, such that the second reinforcement panel 124is inserted through the reinforcement panel cutout 132. The firstdiagonal panel 130 is then folded in the same manner as the firstdiagonal panel 30 the previously described embodiment.

As can be appreciated from FIG. 16, the first reinforcement panel 122extends between the top and bottom panels 28, 22 adjacent to the firstside panel 24 and the second reinforcement panel 124 transverses theinterior cavity perpendicularly to the top, bottom and side panels 22-28(although the second side panel 26 is shown unfolded in FIG. 16 to showdetails of the modified internal support structure). The first andsecond reinforcement panels 122, 124 thereby contribute to the internalsupport structure, further increasing the strength and rigidity of thesupport leg 112.

Referring to FIG. 17, when the first deck retention tab 144 is insertedinto the first deck retention cutout 50, the first deck retention tab144 extends all the way to the first diagonal panel 32, with the anglededge of the tab ears 150 preventing interference between the tab ears150 and the first diagonal panel 32. Similarly, when the second deckretention tab 146 is inserted into the second deck retention tab cutout52 and through the second diagonal deck retention tab cutout 54, thesecond deck retention tab 146 extends all the way to the bottom panel22. Accordingly, the modified deck retention tabs 144, 146 also form apart of the internal support structure, adding even more strength andridigity to the fully folded support leg 112.

The modifications described in this alternate support leg 112 embodimentdo not affect the general manner in which the support leg 112 is securedto the pallet deck 14.

Further modifications to the pallet deck 14 can also be made to add tothe strength, rigidity and functionality of this element. For example,referring to FIG. 18, the pallet deck 114 can include foldable edgepanels 170 substantially surrounding the pallet deck 114. Where adjacentedge panels 170 meet at corners of the pallet deck 114, one edge panel170 is provided with a tab arm 172 and a slot 174 for receiving the tabarm 172 is defined in the other edge panel 170. Referring to FIG. 19,the foldable edge panels 170 are folded up approximately 90 degreesrelative to the rest of the pallet deck (shown mated with a plurality ofsupport legs 12 to form a pallet assembly 110), thus forming a liparound the edge of the pallet deck 114. Insertion of the tab arms 172into the slots 174 maintains the edge panels 170 in the foldedcondition. Products loaded onto the pallet assembly 110 help keep thetab arms 172 engaged in the slots 174. The folded edge panels 170 alongall the edges of the pallet deck 114 increase the strength and rigidityof the pallet assembly 110. The lip formed by the folded edge panels 170also help retain products on the pallet deck 114 and facilitate use ofthe pallet assembly 110 in connection with a hood, or inverted,open-ended box, as used in certain shipping applications.

Referring to FIG. 20, rather than folding the foldable edges 170 up andaway from the support legs 12, the foldable edges 170 can also be foldeddown so as to at least partially conceal the support legs 12. Thisconfiguration provides similar gains in strength and rigidity, and canbe useful, for example, when it is desired to display products for salewithout removing them from the pallet assembly 110. In such a situation,the foldable edge 170 would preferably be folded up during shipping (asin FIG. 19), so as not to interfere with the manipulation of the palletassembly 110 by a forklift, or similar machine. At point of sale, thefoldable edge 170 would be folded down. The side of the foldable edge170 displayed when folded down could be pre-printed with words,pictures, symbols, or the like, and could replace the skirt frequentlyused to conceal pallets holding goods for sale.

The modifications to the pallet deck in this additional embodimentwould, like the alternate support leg embodiment, not affect the generalmanner in which support legs are secured to the pallet deck.

Additionally, various shipping monitoring instruments are advantageouslyutilizable in connection with the present invention. A variety ofshipping monitoring instruments are known in the art, such asradio-frequency identification (RFID) devices and shock, temperature,humidity and inclination indicators. Such devices are desirable to trackarticles to be shipped and/or to monitor the condition of the articlesduring shipping or storage. From various accidental and intentionalcauses, shipping monitoring instruments have a tendency to be removedduring shipping and storage. Accordingly, it is desirable to placeshipping monitoring instruments in locations where they will beprotected from damage and tampering. However, it is also desirable thatthe shipping monitoring be readily readable and/or recoverable byauthorized personnel.

The nested panel structure of the support legs 12, and the mating of thefoldable support legs 12 with the pallet deck 14 afford excellentopportunities for optimal placement of shipping monitoring instruments.For example, a shipping monitoring instrument can be placed on the toppanel 28 (see the location 180 indicated in FIG. 7). When the supportleg 12 is then mated to the pallet deck 14 (see the location 180indicated in FIG. 1), the shipping monitoring instrument is protectedfrom physical damage and concealed from prospective tamperers.

The foregoing is not an exhaustive list of modifications, variations, oradaptations to particular circumstances that can be made within thescope of the present invention. Rather, those skilled in the art willdiscern that these and other variations, modifications and adaptationsto particular circumstances fall within the scope of the invention asherein shown and described.

1. A support leg comprising: a sheet of material configured into asequence of adjacent panels and including a first tab, a first cutoutconfigured to receive the first tab being formed within at least one ofthe panels; wherein the sheet is foldable into a nested panel structurehaving the first tab inserted into the first cutout and defining aninterior cavity.
 2. The support leg of claim 1, wherein the interiorcavity defined by the sheet upon folding has a substantially rectangularcross section.
 3. The support leg of claim 2, wherein a first panel willdiagonally traverse the interior cavity when the sheet is folded intothe nested panel structure.
 4. The support leg of claim 3, wherein asecond panel will diagonally traverse the interior cavity when the sheetis folded into the nested panel structure.
 5. The support leg of claim4, wherein the first and second panels will diagonally traverse theinterior cavity at angles offset by approximately 90 degrees when thesheet is folded into the nested panel structure.
 6. The support leg ofclaim 3, wherein a second cutout for accommodating the first tab afterinsertion into the first cutout is defined in at least one of the panelsdiagonally traversing the interior of the rectangular solid.
 7. Thesupport leg of claim 6, wherein a third and fourth panel define opposingsides of the interior cavity when the sheet is folded into the nestedpanel structure, the first cutout being defined within the third panel,the first tab extending between the third and fourth panels when thefirst tab is inserted into the first cutout.
 8. The support leg of claim5, wherein a third panel defines one of the sides of the rectangularsolid and a fourth panel lies inside of and adjacent to the third panelwhen the sheet is folded into the nested panel structure, the secondpanel extending from the fourth panel.
 9. The support leg of claim 8,wherein the third panel is cut so as to form a second tab, and thefourth panel defines a second cutout, the second tab being insertableinto the second cutout to inhibit unfolding of the support leg when thesheet is at least partially folded into the nested panel structure. 10.The support leg of claim 3, wherein a second panel traverses theinterior cavity substantially perpendicular to the panels defining thesides of the cavity when the sheet is folded into the nested panelstructure.
 11. The support leg of claim 10, wherein a second cutout isdefined within the first panel, the second cutout accommodating thesecond panel when the sheet is folded into the nested panel structure.12. The support leg of claim 2, wherein the first cutout is definedwithin a first panel and the first tab extends from a second panel, thesecond panel overlying at least a portion of the first panel when thesheet is folded into the nested panel structure.
 13. The support leg ofclaim 12, wherein the first and second panels are spaced apart when thesheet is folded into the nested panel structure such that another sheetof material, of at least approximately the same thickness as the sheetof material, can be accommodated between the first and second panels.14. A pallet assembly comprising: a plurality of support legs, at leastone support leg folded from a single sheet of material and including afirst tab and defining a first cutout for receiving the first tabtherein; and a pallet deck, at least one second cutout being definedwithin the pallet deck; wherein the at least one support leg is securedto the pallet deck by the insertion of the first tab through the atleast one second cutout prior to insertion into the first cutout. 15.The pallet assembly of claim 14, wherein the sheet of material formingthe support leg is configured into a sequence of adjacent panels thatare folded into a nested panel structure defining an interior cavity.16. The pallet assembly of claim 15, wherein the interior cavity has asubstantially rectangular cross section and two of the panels diagonallytraverse the interior cavity, the two panels being offset from oneanother by approximately 90 degrees.
 17. The pallet assembly of claim14, wherein the sheet of material folded to form the at least onesupport leg includes a first panel and a second panel, the first cutoutbeing defined within the first panel and the first tab extending fromthe second panel, the pallet deck being accommodated between the firstand second panels.
 18. The pallet assembly of claim 17, wherein at leastone third cutout is defined within the pallet deck, the first tab andthe second panel being inserted through the third cutout prior toinsertion of the first tab through the second cutout.
 19. The palletassembly of claim 14, wherein the pallet assembly further comprises ashipping monitoring instrument, the shipping monitoring instrument beinglocated between the pallet deck and the at least one support leg. 20.The pallet assembly of claim 17, wherein the pallet assembly furthercomprises a shipping monitoring instrument, the shipping monitoringinstrument being located between the pallet deck and the first panel.21. The pallet assembly of claim 14, wherein the pallet deck includes aplurality of foldable edge panels substantially surrounding the palletdeck perimeter.
 22. The pallet assembly of claim 21, wherein theadjacent edge panels are folded away from the support legs to form atray.
 23. The pallet assembly of claim 21, wherein the adjacent edgepanels are folded toward the support legs to form a skirt at leastpartially concealing the support legs.
 24. A pallet deck comprising: asheet of material having a plurality of first cutouts and a plurality ofsecond cutouts defined therein; wherein each first cutout is dimensionedto allow insertion of at least one tab and at least one panel of acorresponding foldable support leg and each second cutout is dimensionedto allow insertion of the at least one tab, each second cutout beingspaced apart from each first cutout such that the at least one panel isable to substantially extend therebetween.
 25. The pallet deck of claim24, wherein there are two second cutouts associated with each firstcutout.
 26. The pallet deck of claim 24, wherein the first cutoutsassociated with support legs to be secured along an edge of the palletdeck are formed as recesses along the edge.
 27. The pallet deck of claim24, wherein the pallet deck includes a plurality of foldable edge panelssubstantially surrounding the pallet deck perimeter.
 28. The pallet deckof claim 27, wherein adjacent foldable edge panels are releasablyconnectable when folded at an angle of approximately 90 degrees relativeto the pallet deck.